Abstract: The two major challenges that industries are facing today are continuous improvement in productivity and quality of the product. An alternative to the Classical and Taguchi experimental design is the lesser known but much simpler Shainin DOE approach. Shainin methods refer to a collection of principles, which make up the framework of a continually evolving approach to quality. Bosch Production System (BPS) - one of the leading manufacturers in Diesel system equipments, has been successfully employing the strong statistical tool ‘Shainin’ for the root cause identification and Design of Experiments (DOE) techniques for analysis and optimization of the quality related issues. Shainin is popular tool being simplest to employ in the manufacturing related problem solving and very effective tool in identifying quality achievement hurdles. The present paper deals with one of the quality issues resolved by using Shainin methodology at Bosch Ltd, Banglore.